Utilized for designing, planning and documenting 3D projects, CAD or computer-aided design, plays an instrumental role in both 3D printing and 3D scanning processes. More specifically, Capture™ a powerful, integrated, industrial-grade 3D scanner and software system, enables us to scan parts without files or faulty dimensions to recover design data and correct manufacturing errors with CAD.

3D scanned mold. Original CAD files did not accompany the mold

Recently, a mold needed to be repaired to a point where the parts made on it would be acceptable for an end-use application for customers. Miller 3D was asked to help with an application that included a two part injection mold, each about 18” x 18”, but a few challenges were presented to Miller 3Dwhile working on this project.

The first problem was the mold was manufactured by a different company and the second was the absence of CAD models or technical drawings for the molds.

When ‘blueprints’ and supporting files are nowhere to be found, this can create a big problem, however, Miller 3D was given the opportunity to use Capture™ to restore dimensional data and make the accurate corrections to the defective molds.

Pat Harrington, an engineer at Miller 3D explains how the molds were prepared for 3D scanning, “We sprayed the mold with a light white powder spray so that our blue light scanner can capture the data points of the complex surface geometry.”

With a data capture rate of 985,000 points/scan and 0.3 sec per scan, Capture™ produces accurate scans to as little as .034 mm — an impressive, precise 3D inspection process completed by the portable device.

“We took multiple scans of the entire mold and meshed them all together into a final 3D CADmodel,” says Harrington.

Detailed view from the 3D scanned file.

Included in multiple scans are automated solid and surface extractions that are featured in PDF reports for engineering teams to analyze for adjustments and corrections. 3D printing garners most of the spotlight, but 3D scanning has the ability to solve application errors, and in return, reduce manufacturing errors, and allow our industry to design from the world around us.

Harrington highlights the importance of the new CAD model generated by Capture™, “This CAD model can be used to help diagnose the issues with the mold in its current state, as well as used as a template for design changes to the mold.”Want to talk more about 3D manufacturing? Miller 3D will be attending the Rapid + TCT 3D Event in Pittsburgh from May 9-11 at booth 911. For more information please visit http://www.rapid3devent.com/.

Miller 3D was given the opportunity to push the boundaries of innovation, manufacturing parts using some of the world’s strongest materials that also maintain integrity when exposed to blistering heat.

Mark X printing the Astronics’ fixture

A local company, Astronics Corporation, a leading supplier of advanced technologies and products to the global aerospace, defense and semiconductor industries, recently had the need for fixtures to support one of their upcoming projects. Astronics’ engineers approached Miller 3D with a project that would ultimately be manufactured with Markforged 3D printed materials.

“Due to the high mechanical properties of Markforged materials, we were able to successfully 3D print many of the required fixtures to fit Astronics’ needs”, Matt Jones, Manager at Miller 3D, explains.

The machine responsible for bringing these fixtures to life is the Mark X, a large 3D printer that can focus down to a 50-micron resolution and build high-strength, precision end-use parts from materials like carbon fiber, or in this case, Onyx.

For reference, the diameter of a human hair is 50 microns, 40 microns is considered the lower limit of visibility of a human eye, and a 25-micron resolution is necessary to see white blood cells.

3D printed fixture made from Onyx

Astronics’ fixtures were printed out of Onyx, which is a chopped carbon fiber nylon mix reinforced with high temperature fiberglass.

Matt adds that continuous fiber high temperature fiberglass was key in maintaining part accuracy and preventing warping during the heating process.

So, how hot? The parameters that these fixtures needed to withstand were 180 degrees Celsius or 356 degrees Fahrenheit for approximately two hours. The Astronics engineers were also able to include geometry into this fixture that could only be 3D printed, not machined, that improved the functionality of the fixture.

A case where engineers can manufacture to true design intent and drastically reduce the cost and timeframe using 3D printing.

Direct metal manufacturing is a process of producing complex metal parts using a high-precision laser. Metal particles melt and mend to previously printed metal layers without the need for an adhesive component. Direct metal printing requires a different approach than 3D printing plastics and other materials.

The final result: the production of parts that can not be created using subtractive and traditional 3D printing technologies.

The absence of an integrated solution was just another layer of difficulty added to an already complex direct metal manufacturing process. In the past, work flow would be interrupted by the presence of several various software solutions to complete one project increasing the odds of an issue; that no longer exists with 3DXpert from 3D Systems.

“There’s never been this level of control in direct metal printing until now,” Matt Jones, Manager at Miller 3D, points out. “Before 3DXpert the user relied on STL file input and limited choices for support generation.”

3DXpert introduces control from design to manufacturing, an asset for users that provides flexibility and simplicity. Furthermore, integrating the entire process reduces the need for different solutions, optimizes and enables you to print quality parts, and shortens the project timeline.

“The fact that 3DXpert can import native CAD files gives the operator full CAD tools directly in the operating environment”, Matt explains. “Support generation tools make it easy to add, delete, create and unlimited amount of support geometries that minimize the efforts in post-processing.”

Also included in the integration solution is the ‘ideal mix’ of tools to automate repetitive tasks while continuing to control every detail of design and manufacturing. 3DXpert also gives ultimate control during the sintering process by allowing a designer to alter the laser parameters in different areas of the part to more reflect the true design intent.

Global support from 3D Systems and the production of quality parts manufactured in reduced time make 3DXpert an integrated solution for all industries.

Feel free to visit the original article by 3DSystems here. We’ve also put it below for your convenience.

Take advantage of continued work with B-rep data (solids and surfaces). Reading B-rep geometry without downgrading to mesh maintains data integrity including analytic geometry, part topology and color coding. This allows preparing the part for printing using history based parametric features.

Start working immediately with automated healing of both STL and B-rep geometry.